Resistance welding machine pinch point safety sensor

ABSTRACT

There is described a continuity sensing system that operates with a resistance-welding machine. This sensing system measures continuity between the welding electrodes after the welding machine has been initiated and prevents application of high electrode force between the electrodes if the continuity measured is below a reference level. The result is a fully passive system that prevents serious high electrode force that would cause serious pinch-point injury to the operator of the welder. The present invention also includes methods of controlling pneumatic systems on resistance-welding machines to apply low force between welding electrodes until continuity between the welding electrodes has been detected.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 12/159,076,filed Jun. 24, 2008, which is a National Stage of InternationalApplication No. PCT/US2006/049131, filed Dec. 21, 2006, which claims thebenefit of U.S. Provisional Application No. 60/755,434, filed Dec. 30,2005, each of which are incorporated by reference in their entirety.

TECHNICAL FIELD

The present invention relates to a monitoring system having voltagepickup wires or contacts connected to the resistance-welding machine'stransformer secondary pads or primary input lines. This connectioncreates a signal which is conditioned and then compared to a voltagereference signal. The output of this sensor system connects to apermissive input on the welding control and through fail-safe logictherein prevents energizing of solenoid valves or other systems thatwould apply high force between the welder's electrodes until metal hasbeen detected between the these electrodes. Methods are also claimedthat will reduce welder ram dead weight to an acceptable level prior toapplication of high electrode force.

BACKGROUND

1. Need for Pinch-Point Protection

Operators of resistance (spot) welding machines are often exposed topotentially serious injury due to the pinch point area between thewelding electrodes. A typical resistance welder operates with electrodeforces of 250 lbs to 5,000 lbs and higher. Because the force isconcentrated on a very small contact surface of the electrode, the forcedensity is extremely high and can easily cause permanent finger injuryor total amputation.

For example, on a welder with 600 lbs of electrode force and a ¼″contact surface, the force density at the pinch point is 12,229 lb/in².Because a common application of a resistance welding machine requiresthe operator to load parts between the electrodes as well as keep theirhands on these parts during the welding sequence, the possibility forserious injury is present on a daily basis. This invention eliminatesserious pinch-point injury by reducing the force between electrodes to avery low level when the operator's finger or other body part is betweenthe electrodes.

2. Prior Art

A typical prior art arrangement will be described with reference toFIGS. 1 to 4. In one form of the prior art arrangement used on directaction welders (“press welders”) and shown in FIG. 1, a limit switch 1is mounted on a fixed portion of the resistance-welding machine frame 2and wired to the welder's control circuitry 3. An adjustable finger 4 ismounted on the moving ram 5 and is adjusted so that the limit switchcloses only after the ram has lowered to the point where space betweenthe electrodes 6 is below the desired dimension (typically about ¼″).After the initiation switch has been closed, the welder's ram 5 falls bygravity, or has some other mechanism to restrict force between theelectrodes until the limit switch 1 has closed. The control circuitry 3,then turns another output on to place full welding force between theelectrodes 6.

A second form of the prior art arrangement is used on rocker arm typewelders and shown in FIG. 2. Force at electrodes 6 is derived from theforce out of the rear piston multiplied by the mechanical advantage ofarms C/B. A limit switch 7 for this prior art device is mounted on afixed portion of the welder frame 2, and an adjustable finger 8 isinstalled on some portion of the welder's moving cylinder mechanism 9.This finger 8 is adjusted so that the limit switch 7 closes only afterthe electrodes 6 have closed to the point where space between them isbelow the desired dimension (typically about ¼″). The control then turnsanother output on to place full welding force between the electrodes 6.

However in both of the above prior arrangements, setting of the limitswitch finger 4 or 8 is done by the operator or setup person, and theaccuracy of this setting is fully in the hands of this person's skill.Furthermore, if the electrodes 6 are moved during normal production orsubsequent electrode replacement or adjustment, and the limit switch isnot adjusted properly, the safety of the system is compromised.

A third form of the prior art arrangement, as shown in FIG. 3, utilizesa system actuated by a motor 9 to close a limit switch 11 (or limitswitch cam). During a setup sequence, an air cylinder is activated tobring the electrodes 6 together. Then the motor 9 moves the switch 11 orcam until the switch is closed by the cam, and then backs it up until aspecific dimension (typically about ¼″) has been reached. During eachwelding sequence, electrodes 6 are moved together under reduced forceuntil the limit switch 11 has been closed. The control then turnsanother output on to place full welding force between the electrodes 6.

This prior art allows automatic setting of the correct spacing betweenelectrodes 6. However, in this third prior art arrangement, propersetting of the cam is mechanical and subject to mechanical adjustmenterrors. Additionally, as with the first two forms, if the electrodes 6spacing is changed during normal production or subsequent electrodereplacement or adjustment, and the operator does not remember to resetthe finger the safety of the system is compromised.

A fourth form of the prior art arrangement, as shown in FIG. 4, utilizesa mechanically or pneumatically moved sensing arm (sometimes called“ring guard”) 11. When the welder is energized during each weldingcycle, the electrodes 6 do not move forward, but this sensing arm 11,lowers to touch ring 11 a to the part 12 being welded. Sensing arm 11 ismechanically designed to encompass the area around the electrodes 6. Ifthe distance traveled is past the set point on a limit switch 13, thesensing arm 11 will retract and the electrodes 6 will be closed underfull welding force. If ring 11 a on the sensing arm 11 does not movethis minimum set distance, as would happen when the operator's finger orother body part is under ring 11 a the sensing arm 11 will retract butthe welder control will not cause the electrodes 6 to close.

However, in this fourth prior art arrangement if the welder operator orsetup person does not adjust the sensing arm 11 properly, high force canbe applied between the welding electrodes 6 even though the operator'sfinger or other body part is between the electrodes. Further, justbending this sensing arm 11 out of the proper sensing zone renders thissystem totally useless.

SUMMARY OF THE INVENTION

The present invention is intended to solve the problems of the prior artpinch point protection for resistance-welding machines. This sensingsystem measures continuity between the welding electrodes after thewelding machine has been initiated and prevents application of highelectrode force between the electrodes if the continuity measured isbelow a reference level. The result is a fully passive system thatprevents serious high electrode force that would cause seriouspinch-point injury to the operator of the welder.

OBJECTS AND ADVANTAGES OF THE INVENTION

It is the object of the invention to provide a pinch point sensingdevice of the character described.

Another object of the present invention to provide a passive sensingsystem that will only allow high electrode force to be applied betweenwelding electrodes if continuity between the electrodes has beendetected, whereby the electrodes will clamp only on any low-resistancematerial, but will not clamp on a high-resistance material such as anoperator's finger or other body part.

Another object is to provide internal sensing of continuity between thewelding electrodes whereby no operator adjustments can be made in eitherthe continuity sensing system or the internal control logic, and,additionally, since the continuity sensing is independent of electrodeposition, the sensing system will protect the pinch point area even ifspacing between the electrodes is changed.

Another object is to provide switching from low to high electrode forcewhich permits limiting electrode force prior to continuity detection andstill provides pinch point protection. Another object is to provide amethod to reduce force between electrodes when the welder ram is closedunder the force of gravity.

The above and other objects, features and advantages of the presentinvention will become more apparent from the following description takenin conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-4, as previously discussed, illustrate prior art systemsattempting to provide suitable pinch point protection for weldingmachines.

FIG. 5 is a block diagram of a system embodying the present inventionusing only a continuity sensor where the sensor signal is obtained fromthe secondary (low voltage) side of the welding transformer according toa preferred embodiment of the present invention, which is the mostcommon type of system.

FIG. 6 is a block diagram of the novel system using only a continuitysensor where the sensor signal is obtained from the primary (highvoltage) side of the welding transformer according to a preferredembodiment of the present invention, which is typically used for weldersthat have remote welding guns with integral transformers such astransguns.

FIG. 7 is a flow chart showing the control logic for the block diagramof FIGS. 5 and 6. when only a continuity sensor system is used, in whichcase the continuity sensor must be closed for the system to allow highwelding force to be applied

FIG. 8 is a flow chart showing the control logic for the block diagramof FIGS. 5 and 6. when both a continuity sensor and a limit switchsystem is used, so that both the continuity sensor and the limit switchmust be closed for the system to allow high welding force to be applied.

FIG. 9 is a pneumatic drawing showing a method embodying the presentinvention for preventing high force between the electrodes on welderswith substantial ram weight, showing the welder at rest.

FIG. 10 is a pneumatic drawing like that of FIG. 9, but with the firststage of the ram dropping by gravity.

FIG. 11 is a pneumatic drawing like that of FIG. 9, with buckingpressure being applied to balance some of the ram's weight.

FIG. 12 is a pneumatic drawing like that of FIG. 9 with full weldingforce being applied if the sensor(s) has been satisfied.

FIG. 13 is a pneumatic drawing of a typical welder embodying the presentinvention which is at rest that has a ram without substantial deadweight which will not close under gravity and which typically has arocker arm welder or a welder using a fixture type package cylinder.

FIG. 14 is a pneumatic drawing similar to FIG. 13 with low force beingapplied for travel of the electrode prior to the sensor(s) beingsatisfied.

FIG. 15 is pneumatic drawing similar to FIG. 13 with full force beingapplied if the sensor(s) has been satisfied.

FIG. 16 illustrates the mechanical arrangement of a typical welderembodying the present invention that has a ram without substantial deadweight but that will close under gravity when air is removed from thecylinder.

FIG. 17 is a pneumatic drawing for a system shown at rest to preventhigh force applied between the electrodes, similar to that shown in FIG.16.

FIG. 18 is a pneumatic drawing of the system shown in FIG. 17 with theram falling by gravity (weight of weld ram).

FIG. 19 is a pneumatic drawing of the system shown in FIG. 17illustrating application of full welding force if the sensor(s) has beensatisfied.

DETAILED DESCRIPTION Preferred Embodiments of the Invention

A resistance-welding machine according to a preferred embodiments of theinvention will be described with reference to FIGS. 5 through 19.

FIG. 5 shows the electronic diagram of a typical resistance-weldingmachine that has only a continuity sensor 20 as the detection system,with components of the preferred embodiment of the invention. When thewelding electrodes 18 are not in contact, a low voltage leakage isdeveloped by a resistor/capacitor element 14, connected across the SCRcontactor 15 to put low voltage on the welding transformer's primaryside 16. The continuity sensor 20 may also include an isolationtransformer 20A, an operational amplified/integrator 20B and a RMSconverter 20C, as shown in FIG. 5.

This voltage is transmitted inductively to the welding transformer'ssecondary 17 and to the welding electrodes 18. A pair of wires 19 orcontacts are connected across the welding transformers secondary 17,ideally at the points closest to the transformer's output keep thesensor wires out of the mechanical area of the welder, and to the inputof the continuity sensor 20.

During a welding sequence, the welding controller 25 energizeslow-pressure solenoid valve, 27. The welding electrodes 18 are nowbrought together under low force by the welding controller. If thesewelding electrodes 18 contact low-resistance metal to be welded,impedance of the welder secondary 17 is lowered.

Since available current from R/C element 14 is very low, the loweredimpedance of the secondary 17 greatly reduces voltage from this R/Celement on the transformer primary 16 to inductively reduce voltage ontransformer secondary 17. This lowered voltage at secondary 17 istransmitted through wires 19 to the input of continuity sensor, 20. Thefirst stage of continuity sensor 20 conditions this input voltage. Thecontinuity sensor 20 may include an isolation transformer 20A, anoperational amplifier/integrator 20B, and an RMS converter 20C. Theconditioned voltage is fed into comparator 22. If this conditioned inputvoltage level goes below the comparator's reference voltage relay 23 isenergized. Normally open contacts 24 on this relay are closed to signalwelding controller 25 that continuity has been detected between theelectrodes 18.

Adjustment of the internal reference voltage will match electricalresponse of the welder to close and open electrode conditions fordifferent types of welders. At this time, logic in welding controller 25energizes solenoid valve 26 to put full welding force between weldingelectrodes 18. However, if this conditioned reference voltage fails togo below the reference voltage of comparator 22 within a time limit,controller 25 releases low-pressure solenoid valve 27, and electrodes 18open without ever reaching full force. At the same time, a diagnosticcan be displayed on welding controller 25.

Alternately, as shown in FIG. 6, a voltage parallel to the weldingtransformer's primary 16 is connected by wires 29 to a step-downtransformer 28 and then to the input of the continuity sensor with wires30. The circuitry of the continuity sensor 20 conditions this inputsignal to eliminate extraneous voltage and prevent high welding (orline) voltage from damaging the low-level circuitry in the system'scomparator 22. Similar to FIG. 5, the continuity sensor 20 may alsoinclude an operational amplified/integrator 20B and a RMS converter 20C,as shown in FIG. 6.

During a welding sequence, the welding controller 25, energizeslow-pressure solenoid valve 27. If welding electrodes 18 contactlow-resistance metal 21 being welded, impedence of the weldingtransformers secondary is greatly lowered. Since the available currentfrom the R/C element 14 is very low, the lowered impedance of thetransformer's secondary reduces voltage from this R/C element on thetransformer primary 16. This lowered and isolated voltage is transmittedthrough wires 29 through a step-down transformer 28 and to input of thecontinuity sensor 20.

The first stage of the continuity sensor 20, conditions this inputvoltage. The conditioned voltage is fed into a comparator 22. If thisconditioned input voltage level goes below the reference voltage of thecomparator 22, relay 23 is energized. Normally open contacts 24 on thisrelay 23 are closed to signal the welding controller 25 that continuityhas been detected between the electrodes 18.

Adjustment of the internal reference voltage will match electricalresponse of the welder to close and open electrode conditions fordifferent types of welders. At this time, logic in the weldingcontroller energizes a high pressure solenoid valve 26 to put fullwelding force between welding electrodes 18. However, if thisconditioned reference voltage fails to go below the reference voltage ofthe comparator 22 within a time limit, the controller 25 releaseslow-pressure solenoid valve 27, and the electrodes 18 open without everreaching full force. At the same time, a diagnostic can be displayed onthe welding controller 25.

FIG. 7 shows the logic sequence according to the preferred embodiment ofthis invention on a welder using the electronic diagram of FIGS. 5 and6. After the welder's initiation switch has been closed, the controlchecks to see if continuity sensor output relay contact 24 that isconnected to the control “continuity sensor input” has closed.

Sequences of Operation (FIG. 5 and FIG. 6 Embodiment)

Sequence 1: Continuity sensor input is not closed at start: The controlturns on the low-pressure solenoid valve 27 to bring the electrodesclosed under low force. The control continues to monitor the continuitysensor input.

Sequence 1a: If the continuity sensor input is not closed within theselected maximum set detect time, the low-force solenoid valve 27 isturned off to open the electrodes, a display fault is shown on thecontrol, and the system locks out until the initiation switch has beenopened.

Sequence 1b: If the continuity sensor input closes before the selecteddetect time has elapsed, the high-force solenoid valve 26 is closed toput full force on the electrodes 18. The control then goes through theweld sequence and finally turns off both solenoid valves 26 and 27 torelease the electrodes 18.

Sequence 2: Continuity sensor input is closed at the start. Because thisindicates a failure of the continuity sensor 20, a faulty setting of thecontinuity sensor board, an incorrect setting of the reference voltage,or a short in the detector wires (19 in FIG. 5, 29 in FIG. 6), thecontroller 25 does not energize the low-force solenoid valve 27 andlocks out waiting for the initiation switch to be opened before allowingthe next attempted cycle. At the same time, a fault indication is shownon the display.

FIG. 8 shows a flow chart for an alternate logic sequence that requiresthe detection of continuity as illustrated above plus closing of aram-position limit switch before allowing full electrode force. Thisarrangement is typically used for welding of parts that are not flat atthe beginning of the welding sequence, or where a redundant sensor isdesired.

The limit switch, like that shown in FIG. 1, is mechanically adjusted sothat a cam will close this limit switch if electrodes 6 are closer thana desired dimension (typically about ¼″). The same logic can be used onrocker arm welders using limit switch 7 and adjustable finger 8 in FIG.2; and a motorized set limit switch 11 like that shown in FIG. 3 maybeen used.

The logic chart shown in FIG. 8 shows the logic sequence with thissecond detection element according to the preferred embodiment of thisinvention. After the welder's initiation switch has been closed, thecontrol checks to see if both the continuity sensor input and the limitswitch contacts have been closed

Sequences of Operation (FIG. 8 Embodiment)

Sequence 1: Neither continuity sensor nor limit switch contact closureis detected at start: The control turns on the low-pressure solenoidvalve to bring the electrodes closed under low force. The controlcontinues to monitor both input signals.

Sequence 1a: If contact closure from both the continuity sensor and thelimit switch are not detected within the predetermined selected detecttime, the low-force solenoid valve is turned off to open the electrodes,a display fault is shown on the control, and the system locks out untilthe initiation switch has been opened.

Sequence 1b: If contact closure from both the continuity detector andthe limit switch is detected before the detect time has elapsed, thehigh-force solenoid valve is energized to put full force on theelectrodes. The control then goes through the weld sequence and finallyturns off both solenoid valves to release the electrodes.

Sequence 2: Contact closure from either one or both inputs is detectedat the start. Because this indicates a continuity circuit failure orfaulty setting of the reference voltage, a short in the detector wires,or an improperly set or permanently closed limit switch, the controldoes not energize even the low-force solenoid valve and locks outwaiting for the initiation switch to be opened before allowing the nextattempted cycle.

Mechanical Methods for Attaining Low Approach Force.

Methods of mechanical operation to provide both low and high forcebetween the electrodes are required to utilize the logic of the presentinvention. Different mechanical arrangements of pneumatic and othercomponents are required to operate different types of resistance weldingmachines. This section covers the most common welding systems. Howeverthe use of the present invention is not limited to this machinery group.

Welders with Significant Ram Weight:

Force between electrodes produced by gravity closure (weight of the ram)alone on this type of welder is high enough to cause significant pinchpoint injury. FIG. 1 illustrates a press welder that typically utilizesa guided ram containing an electrode holder, and is activated by acylinder. The cylinder can be operated directly or indirectly, by air,hydraulics, or a hybrid of the two.

In the preferred embodiment of this invention, a system is installed topartially counterbalance the gravity dead weight of the ram during theinitial stages of each cycle and until continuity between the electrodeshas been established.

A preferred arrangement for a pneumatically operated cylinder to operatea press welder is shown in FIG. 9. In this figure, the welder is at restwith the electrodes fully opened. Line pressure air from 5-way solenoidvalve 39 is reduced by regulator 40 and passes through 3-way solenoidvalve 41 through flow control valve 42, to shuttle valve 43. Because atthis time there is no air pressure on the other input port of thisshuttle valve, this air passes through the shuttle valve 43 and then tothe bottom of the air cylinder at port 44. Since there is no airpressure on the top cylinder port 45 air pressure on the underside ofthe welder cylinder piston 46 keeps the welder cylinder in the retractedposition to keep the electrodes fully apart.

The sequence of events during a typical welding cycle is shown in FIG.10. When the welding control is first initiated (closing of foot orother switch), three way solenoid valve 41 is energized to exhaust airfrom the bottom of the welder cylinder at port 44 through the shuttlevalve 43 and to flow control valve 42. The airflow is metered by thisflow control valve and moves through 3-way solenoid valve 41 to thisvalve's exhaust.

Lowering of air pressure on the underside of piston 46 causes thecylinder piston to drop under the force of gravity. As this happens,downward movement of the welder cylinder piston 46 pushes air out oflower port 44. Because this airflow is restricted by flow control valve42 air in the lower portion of this cylinder is partially compressed toimpose a backpressure on the underside of piston 46. This back pressureimposes an upward force on piston 46 to partially reduce thegravity-produced weight of the welder's ram.

As shown in FIG. 11, when air pressure at the solenoid valve side 47 ofshuttle valve 43 drops to a pressure lower than that at regulator side48 of this shuttle valve, the shuttle valve shifts to block additionalexhaust through solenoid valve 41 and imposes air pressure of regulator49.

This air pressure on the underside of piston 46 continues to impose anupward force on this piston to partially balance the gravity-producedweight of the welder's ram. At this stage of the sequence, force inpounds between the welding electrodes 50 is represented by the formula:F=RW−(psi×A)

-   -   Where:    -   F=force between electrodes in pounds    -   RW=gravity weight of welder ram in pounds    -   psi=air pressure of regulator 49 in psi

A=underside area of welder cylinder piston 46 in² Force can also becalculated using the appropriate formula for metric measurements.

FIG. 12 shows the sequence that follows if the input contact is closedfrom the continuity sensor (or both continuity sensor and limit switchif so installed) to the welding control within the maximum customer-setsensor time.

At this time, the control energizes solenoid valve 39 while stillkeeping solenoid valve 41 energized. This puts higher-pressure air, assupplied from regulator 50, on the top of the welder cylinder at port45, and exhausts air from the bottom of the welder cylinder 44 throughshuttle 43, through pressure regulator 49, and out the exhaust ofsolenoid 39.

When the sequence has been completed, the air on the top of the weldingcylinder piston 46 will be at the level of pressure regulator 50, andthe air on the bottom of the welding cylinder piston will be zero. Thewelding electrodes will now be at full force for welding.

At this stage of the sequence, force in pounds between the weldingelectrodes 50 is represented by the formula:F=psi×A

-   -   Where:    -   F=force between electrodes in pounds    -   psi=air pressure of regulator 50, in psi    -   A=top area of welder cylinder piston 46 in²

After the weld sequence has been completed, the welding control willdeenergize both solenoid valves 39, and 41 to return the welder cylinderpiston 46 to the retraced position of FIG. 9. If the input is not closedfrom the continuity sensor (or both continuity sensor and limit switchif so installed) to the welding control within the maximum customer-setsensor time, solenoid valve 39 will not be energized, and solenoid valve41 will be de-energized to return the welder cylinder piston 46 to theretraced position of FIG. 9.

Welders without Significant Ram Weight,

And Will not Close Under Gravity;

These welder types require a different pneumatic scheme for operation.

Rocker Arm:

The typical mechanical design of one type, a rocker arm welder, is shownin FIG. 2. This type of welder typically utilizes a pivoted beamarrangement with an air cylinder on one end of the beam to close theelectrodes in the opposite direction on the other end of the beam.

Unless the beam is very long and made of very heavy material, forcebetween electrodes on this type of rocker arm welder is normally zero orvery low when air is exhausted from the welding cylinder. In most cases,the electrodes will not even close when air is removed from thecylinder.

Low Ram Weight Press Welders:

A second type, as shown in FIG. 1, is a press welder that contains a ramthat does not have significant weight to overcome friction in the weldercylinder and will not close the electrodes by gravity when air isremoved from the welder cylinder.

A preferred arrangement for operating the welding cylinder of these twowelder types is shown in FIG. 13. In this figure, the welder is at rest,with the electrodes 52 fully open.

In the preferred embodiment of the present invention, regulated air fromregulator 54 goes through 5-way solenoid valve 55 and to port 56 of thewelder cylinder. This imposes air pressure on the underside of thewelder cylinder piston, 57 to keep the welder cylinder piston in theretracted position and the electrodes, 53 open. On a rocker arm welder,this air cylinder is typically installed inverted from the illustrationas shown in FIG. 2, but the action within the welder cylinder isidentical.

The sequence of events during a typical welding cycle starts as shown inFIG. 14. When the welding control is first initiated (closing of foot orother switch), five-way solenoid valve 55 is energized to exhaust airfrom the bottom of the welder cylinder 56 out the exhaust port ofsolenoid valve 55 using flow control valve 57 to meter the airflow andcontrol the closing speed. At the same time, low-pressure air issupplied from pressure regulator 58 through 5-way solenoid valve 55 toport 62 on shuttle valve 60. Because at this time there is no pressurecoming into port 63 of the shuttle valve, this low-pressure regulatedair passes through to port 61 on the welder cylinder. This moves thewelder piston 57 forward under low force until electrodes 53 touch.Force, in pounds, between the electrodes at this stage of the sequencefor a press welder is represented by the formula:F=psi×A

-   -   Where:    -   F=force between electrodes in pounds    -   psi=air pressure of regulator 58, in psi    -   A=top area of welder cylinder piston 57 in²    -   Force, in pounds, between the electrodes at this stage of the        sequence for a rocker arm welder, is represented by the formula        F=C/B×(psi×A)    -   Where:    -   F=force between electrodes in pounds    -   psi=air pressure of regulator 58, in psi    -   A=top area of welder cylinder piston 57 in²    -   B and C=dimensions from FIG. 2    -   Force can also be calculated for either press or rocker arm        systems using the appropriate formula for metric measurements.

FIG. 15 shows the sequence that follows if the input contact is closedfrom the continuity sensor (or both continuity sensor and limit switchif so installed) to the welding control within the maximum customer-setsensor time. At this time, the control energizes solenoid valve 59 whilestill keeping solenoid valve 55 energized. This puts higher-pressureair, as supplied from regulator 64, into port 63 of shuttle valve 60 toshift the shuttle valve and pu higher pressure air on the top of thewelder cylinder at port 61.

Force, in pounds, between the electrodes at this stage of the sequencefor a press welder is represented by the formulaF=psi×A

-   -   Where:    -   F=force between electrodes in pounds    -   psi=air pressure of regulator 64, in psi    -   A=top area of welder cylinder piston, 57, in²

Force, in pounds, between the electrodes at this stage of the sequencefor a rocker arm welder, is represented by the formulaF=C/B×(psi×A)

-   -   Where:    -   F=force between electrodes in pounds    -   psi=air pressure of regulator 64, in psi    -   A=area of welder cylinder piston 57 in²    -   B and C=dimensions from FIG. 2    -   Force can also be calculated using the appropriate formula for        metric measurements or for welder cylinders that use        air-over-oil intensifier systems.

After the weld sequence has been completed, the welding control willdeenergize both solenoid valves 55, and 59 to return the welder cylinderpiston 57 to the retraced position of FIG. 13.

If the input is not closed from the continuity sensor (or bothcontinuity sensor and limit switch if so installed) to the weldingcontrol within the maximum customer-set sensor time, solenoid valve 59will not be energized, and solenoid valve 55 will be de-energized toreturn the welder cylinder piston 57 to the retraced position of FIG.13.

Welders without Significant Weight

But that Close Under Gravity:

This type of welder can use a much more simple arrangement to utilizethe features of this invention. The mechanical arrangement for a presswelder, as shown in FIG. 16, has enough ram weight to allow it to closeunder gravity but is light enough to prevent pinch point damage undergravity closing is. This type of welder typically utilizes a guided ram65 that contains an electrode holder 66 and is activated by a cylinder67. The cylinder can be operated directly or indirectly, by air,hydraulics, or a hybrid of the two.

A preferred arrangement for a pneumatically operated cylinder is shownin FIG. 17. In this figure, the welder is at rest with the electrodesfully opened. Line pressure air is reduced by regulator 69 and passesthrough 3-way solenoid valve 70 to impose air pressure on the undersideof the welder cylinder piston, 71. This keeps the welder cylinder open.

The sequence of events during a typical welding cycle starts as shown inFIG. 18. When the welding control is first initiated (closing of foot orother switch), three-way solenoid valve 70 is energized to exhaust airfrom the bottom of the welder cylinder using flow control valve 73 tometer the airflow and control the closing speed until the electrodestouch.

Force, in pounds, between the electrodes 77 at this stage of thesequence is the dead gravity weight of the welder's ram 74.

FIG. 19 shows the sequence that follows if the input contact is closedfrom the continuity sensor (or both continuity sensor and limit switchif so installed) to the welding control within the maximum customer-setsensor time. At this time, the control energizes three-way solenoidvalve 75 while still keeping solenoid valve 70 energized. This puts air,as supplied from regulator 76, on the top of the welder cylinder at port77. Force, in pounds, between the electrodes at this stage of isrepresented by the formula:F=psi×A

-   -   Where:    -   F=force between electrodes in pounds    -   psi=air pressure of regulator 76, in psi    -   A=top area of welder cylinder piston in²    -   Force can also be calculated using the appropriate formula for        metric measurements or for welder cylinders that use        air-over-oil intensifier systems,    -   Welders that Use Servo Motors or Other Motor Driven Systems:

This type of welder utilizes a motor-driven mechanism to close theelectrodes. The system embodying this invention communicates with theservo control circuitry to provide low torque prior to electrodecontinuity detection. If continuity is not detected prior to the maximumdetection time has expired, the low-force signal to the servo controlcircuitry will be turned off to force the servo system to return theelectrode to the fully open position.

While embodiments of the invention have been shown in considerabledetail, it is not intended that the inventions should be limited to theexact construction described and many changes and modifications of thestructure and methods can be made without departing from the spirit orscope of the invention.

What is claimed is:
 1. A welding machine comprising: a pneumaticcylinder including a first side and a second side; a first low pressureregulator configured to output a counterbalancing pneumatic pressure; asecond low pressure regulator configured to output a bucking pneumaticpressure, wherein the bucking pneumatic pressure is lower than thecounterbalancing pneumatic pressure; a sensor system configured todetect at least one condition relating to a pair of welding electrodesand to determine whether the welding machine is permitted to complete aweld; and a plurality of valves configured to: during a first time,apply the counterbalancing pneumatic pressure output from the first lowpressure regulator to the first side of the pneumatic cylinder to fullycounterbalance a dead weight of a welding ram of the welding machine tokeep the pair of welding electrodes apart; during a second timeoccurring after the first time, exhaust at least some air from the firstside of the pneumatic cylinder to reduce a pressure on the first side ofthe pneumatic cylinder to be lower than the counterbalancing pneumaticpressure to bring the pair of welding electrodes together under aportion of the dead weight of the welding ram; during a third timeoccurring after the second time, apply the bucking pneumatic pressureoutput from the second low pressure regulator to the first side of thepneumatic cylinder to partially counterbalance the dead weight of thewelding ram to keep the pair of welding electrodes together under aforce lower than the dead weight of the welding ram; and during a fourthtime occurring after the third time, apply the welding pneumaticpressure to a second side of the pneumatic cylinder to apply a weldingforce to the pair of welding electrodes only when the sensor systemdetermines that the welding machine is permitted to complete the weld.2. The welding machine of claim 1, wherein the plurality of valves arefurther configured to, during the fourth time, exhaust all pneumaticpressure from the first side of the pneumatic cylinder.
 3. The weldingmachine of claim 1, wherein the plurality of valves comprises: a flowcontrol valve configured to, during the second time, meter the exhaustof the air from the first side of the pneumatic cylinder to slow amovement of at least one of the pair of electrodes while bringing thepair of electrodes together.
 4. The welding machine of claim 1, whereinthe sensor system comprises a continuity sensor configured to: sense anelectrical continuity level between the electrodes; and determinewhether the welding machine is permitted to complete the weld bydetermining that the electrical continuity exceeds a continuityreference level prior to applying the welding pneumatic pressure to thesecond side of the pneumatic cylinder during the fourth time.
 5. Thewelding machine of claim 1, wherein the plurality of valves are furtherconfigured to: during a fifth time occurring after the third time andoccurring instead of the fourth time, apply the counterbalancingpneumatic pressure to the first side of the pneumatic cylinder to movethe pair of welding electrodes apart when the sensor system determinesthat the welding machine is not permitted to complete the weld.
 6. Thewelding machine of claim 5, wherein the sensor system is configured todetermine that the welding machine is not permitted to complete the weldin response to the sensor system failing to detect the at least onecondition relating to the pair of welding electrodes prior to anexpiration of a timer.
 7. The welding machine of claim 5, wherein thesensor system comprises a continuity sensor configured to: sense anelectrical continuity level between the electrodes; and determine thatthe welding machine is not permitted to complete the weld by determiningthat the electrical continuity does not exceed a continuity referencelevel prior to an expiration of a timer.
 8. The welding machine of claim1, wherein the sensor system comprises a limit switch configured todetect when the pair of welding electrodes have been brought together toa distance less than a distance threshold, and wherein the sensor systemis configured to determine whether the welding machine is permitted tocomplete the weld by determining that the pair of welding electrodeshave been brought together to the distance less than the distancethreshold prior to applying the welding pneumatic pressure to the secondside of the pneumatic cylinder during the fourth time.
 9. The weldingmachine of claim 1, wherein the plurality of valves comprises: a firstvalve configured to: operate in a first configuration during the secondtime, wherein the first configuration comprises the first valve beingconfigured to allow the at least some of the air from the first side ofthe pneumatic cylinder to be exhausted; and operate in a secondconfiguration during the third time, wherein the second configurationcomprises the first valve being configured to allow the bucking pressureto be applied to the first side of the pneumatic cylinder; wherein, thefirst valve is configured to change from the first configuration to thesecond configuration when a pressure in the first side of the pneumaticcylinder falls below the bucking pressure.
 10. The welding machine ofclaim 9, wherein the first valve functions as a shuttle valve.
 11. Awelding machine controller configured to couple to a pneumatic pressuresource, a first side of a pneumatic cylinder of a welding machine, and asecond side of the pneumatic cylinder, the welding machine controllercomprising: a first low pressure regulator configured to receive thepneumatic pressure source and output a counterbalancing pneumaticpressure; a second low pressure regulator configured to output a buckingpneumatic pressure, wherein the bucking pneumatic pressure is lower thanthe counterbalancing pneumatic pressure; a sensor system configured todetect at least one condition relating to a pair of welding electrodesand to determine whether the welding machine is permitted to complete aweld; and a plurality of valves configured to: during a first time,apply the counterbalancing pneumatic pressure output from the first lowpressure regulator to the first side of the pneumatic cylinder to fullycounterbalance a dead weight of a welding ram of the welding machine tokeep the pair of welding electrodes apart; during a second timeoccurring after the first time, exhaust at least some air from the firstside of the pneumatic cylinder to reduce a pressure on the first side ofthe pneumatic cylinder to be lower than the counterbalancing pneumaticpressure to bring the pair of welding electrodes together under aportion of the dead weight of the welding ram; during a third timeoccurring after the second time, apply the bucking pneumatic pressureoutput from the second low pressure regulator to the first side of thepneumatic cylinder to partially counterbalance the dead weight of thewelding ram to keep the pair of welding electrodes together under aforce lower than the dead weight of the welding ram; and during a fourthtime occurring after the third time, apply the welding pneumaticpressure to a second side of the pneumatic cylinder to apply a weldingforce to the pair of welding electrodes only when the sensor systemdetermines that the welding machine is permitted to complete the weld.12. The welding machine controller of claim 11, wherein the plurality ofvalves are further configured to, during the fourth time, exhaust allpneumatic pressure from the first side of the pneumatic cylinder. 13.The welding machine controller of claim 11, wherein the plurality ofvalves comprises: a flow control valve configured to, during the secondtime, meter the exhaust of the air from the first side of the pneumaticcylinder to slow a movement of at least one of the pair of electrodeswhile bringing the pair of electrodes together.
 14. The welding machinecontroller of claim 11, wherein the sensor system comprises a continuitysensor configured to: sense an electrical continuity level between theelectrodes; and determine whether the welding machine is permitted tocomplete the weld by determining that the electrical continuity exceedsa continuity reference level prior to applying the welding pneumaticpressure to the second side of the pneumatic cylinder during the fourthtime.
 15. The welding machine controller of claim 11, wherein theplurality of valves are further configured to: during a fifth timeoccurring after the third time and occurring instead of the fourth time,apply the counterbalancing pneumatic pressure to the first side of thepneumatic cylinder to move the pair of welding electrodes apart when thesensor system determines that the welding machine is not permitted tocomplete the weld.
 16. The welding machine controller of claim 15,wherein the sensor system is configured to determine that the weldingmachine is not permitted to complete the weld in response to the sensorsystem failing to detect the at least one condition relating to the pairof welding electrodes prior to an expiration of a timer.
 17. The weldingmachine of claim 15, wherein the sensor system comprises a continuitysensor configured to: sense an electrical continuity level between theelectrodes; and determine that the welding machine is not permitted tocomplete the weld by determining that the electrical continuity does notexceed a continuity reference level prior to an expiration of a timer.18. The welding machine of claim 11, wherein the sensor system comprisesa limit switch configured to detect when the pair of welding electrodeshave been brought together to a distance less than a distance threshold,and wherein the sensor system is configured to determine whether thewelding machine is permitted to complete the weld by determining thatthe pair of welding electrodes have been brought together to thedistance less than the distance threshold prior to applying the weldingpneumatic pressure to the second side of the pneumatic cylinder duringthe fourth time.
 19. The welding machine of claim 11, wherein theplurality of valves comprises: a first valve configured to: operate in afirst configuration during the second time, wherein the firstconfiguration comprises the first valve being configured to allow the atleast some of the air from the first side of the pneumatic cylinder tobe exhausted; and operate in a second configuration during the thirdtime, wherein the second configuration comprises the first valve beingconfigured to allow the bucking pressure to be applied to the first sideof the pneumatic cylinder; wherein, the first valve is configured tochange from the first configuration to the second configuration when apressure in the first side of the pneumatic cylinder falls below thebucking pressure.
 20. The welding machine of claim 19, wherein the firstvalve functions as a shuttle valve.